DESIGN AND FABRICATION OF MEDIUM THICKNESS

COMPOSITE CUTTER
A PROJECT REPORT

Submitted by

VIVEK KUMAR PANDEY (1501061110)

DEEPAK SHARMA (1501061275)

GAURAV SHAH (1501061109)

ARPIT GULERIA (1501061170)

In partial fulfillment for the award of the degree Of

B.TECH
IN

MECHANICAL ENGINEERING

UNDER THE GUIDANCE OF

Mr. P.S. Chandel

DEPARTMENT OF MECHANICAL ENGINEERING

DIT UNIVERSITY

(i)
 Declaration
I declare that this project submission represents my ideas in my own words, and where others’
ideas and words have been included. I have adequately cited and referenced the original sources.
I also declare that I have adhered to all the principle of academic honesty and integrity and have
not misinterpreted or fabricated or falsified any idea/data/fact/source in my submission. I
understand that any violation of the above will be cause for disciplinary action by the University.

Signature

VIVEK KUMAR PANDEY (1501061110)

DEEPAK SHARMA (1501061275)

GAURAV SHAH (1501061109)

ARPIT GULERIA (1501061170)

Date:

( ii )
 Certificate

This is to certify that the project report entitled “DESIGN AND FABRICATION OF
MEDIUM THICKNESS COMPOSITE CUTTER,” submitted by “Vivek kumar pandey
(1501061110), Deepak sharma (1501061275), Gaurav shah (1501061109) and Arpit guleria
(1501061170)” in partial fulfillment of the requirements for the award of Bachelor of
Technology in the stream of Mechanical Engineering, DIT University, Dehradun is a bonafide
work carried out under our supervision.

Signature

Prof. P.S. Chandel

Asst. professor

Department of Mechanical Engineering

External Examiner 1 External Examiner 2

Head of Department

DEPARTMENT OF MECHANICAL ENGINEERING

DIT UNIVERSITY

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 Acknowledgements

I feel much honoured in presenting this dissertation report in such an authenticable form of sheer
endurance and continual efforts of inspiring excellence from various coordinating factor of
cooperation and sincere efforts drawn from all sources of knowledge. I express my sincere
gratitude to Mr. P.S.Chandel, Professor, MECHANICAL ENGINEERING DEPARTMENT,
DIT UNIVERSITY.

I wish to express my profound gratitude to Professor, Dr. Manoj Kumar, MECHANICAL

ENGINEERING DEPARTMENT, DIT UNIVERSITY for his support and providing all the
facilities, which would have made it possible for me to complete the dissertation report. The
cooperation he gave is greatly appreciated.

I extend my thanks to all classmates who have given their full cooperation and valuable
suggestion for my dissertation report work.

VIVEK KUMAR PANDEY (1501061110)

DEEPAK SHARMA (1501061275)

GAURAV SHAH (1501061109)

ARPIT GULERIA (1501061170)

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 ABSTRACT

The primary object of the project is to design and fabricate the composite/sheet metal/wood/glass
fiber cutter for cutting any profile of medium thickness. The adjustable tool setup is provided
thereby for smooth cutting. The cutting machine is electrically operated using a motor of 1 hp
(singe phase). The cutter in the machine can be changed according to composite/sheet
metal/wood/glass fiber which is to be cut.
For example: for Cutting of glass fiber tungsten carbide cutter is used which will keep the cutting
process smooth and will give a good finish. The machine is portable in size so can be easily
transportable.

Cooling mechanism is also provided to obtain a better surface finish and smooth cutting
operation.

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CONTENTS Page no.
Declaration…………………………………………………………………………………….(ii)

Certificate……………………………………………………………………………………..(iii)

Acknowledgement…………………………………………………………………………….(iv)

Abstract………………………………………………………………………………………..(v)

List of Figures…………………………………………………………………………………(vii)

CHAPTER 1 INTRODUCTION

1.1.MOTOR…………………………………………………………………………………1

1.2 PULLEY-BELT…………………………………………………………………………3

1.3 BEARINGS……………………………………………………………………………...5

1.4 SHAFT…………………………………………………………………………………..7

1.5 FRAME………………………………………………………………………………….8

1.6 CUTTER…………………………………………………………………………………9

CHAPTER 2 MATERIAL

(2.1) MATERIAL PROPERTIES…………………………………………………………...10

CHAPTER 3 CALCULATIONS………………………………………………………….12

CHAPTER 4 CATIA DESIGN…………………………………………………………...20

CHAPTER 5 BILL OF MATERIALS…………………………………………………...24

CHAPTER 6 REFERENCE………………………………………………………………25

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LIST OF FIGURES Page No.

Electric Motor……..........................................................................................................1

Pulley Belt Mechanism…………………………………………………………………4

Bearing…………………………………………………………………………………5

Metal cutting………………………………………………………………………..16,17

Drilling……………………………………………………………………………...18,19

Catia Design……………………………………………………………………………20

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 CHAPTER-1

ELECTRIC MOTOR

An electric motor is an electrical machine that converts current into energy. Most electrical
motors operate through the interaction between the motor's flux and therefore the current
Associate in Nursing exceedingly|in a very} wire winding to come up with force within the type
of an axis rotation. electrical motors is hopped-up by DC (DC) sources, like batteries, motorcars
or rectifiers, or electrical energy (AC) sources, like associate degree electrical network, electrical
converter or electrical generators. an electrical generator is automatically clone of an electrical
motor, however works within the wrong way, changing energy into current.
Electric motors can be classified based on considerations such as the type of power supply, the
internal construction, the application and the type of movement output. In addition to the types of
AC with respect to CC, the motors can be brushed or brushless, they can be of different phases
(see single-phase, two-phase or three-phase) and can be cooled by air or liquid. General purpose
engines with standard dimensions and features provide convenient mechanical power for
industrial use. The largest electric motors are used for marine propulsion storage, pipe
compression and pumping applications with nominal values up to 100 megawatts. Electric
motors are found in industrial fans, fans and pumps, machine tools, electrical appliances, electric
tools and disk drives. Small engines can be found in electric watches.

In some applications, like in regenerative braking with traction motors, electrical motors is used
on the contrary as generators to recover energy that will somewhat be lost within the kind of heat
and friction.
Electric motors manufacture a linear or rotating force (torque) and might be distinguished from
devices like magnetic solenoids and speakers that convert electricity into motion however don't
generate a usable mechanical force, that refers to actuators and transducers severally.

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Components
Rotor: - In an electrical motor, the moving half is that the rotor, that rotates the shaft to supply
mechanical power. The rotor typically has conductors organized that carry currents that move
with the field of force of the stator coil to come up with the forces that build the shaft rotate. or
else, some rotors carry permanent magnets and therefore the stator coil supports the conductors.

Bearings: - The rotor is supported by bearings which allow the rotor to rotate on its axis. The
bearings are in turn supported by the motor housing. The crankshaft extends through the bearings
to the outside of the engine, where the load is applied. Since the load forces are exerted beyond
the outermost bearing, the load is said to be flown over.

Stator: - The stator coil is that the mounted a part of the magnetic force circuit of the motor and
usually consists of windings or permanent magnets. The stator coil core consists of the many
skinny plates, known as laminations. Laminates area unit wont to cut back energy losses that
may occur if a solid core were used.

Airspace: - The distance between the rotor and the stator is called airspace. Airspace has
important effects, and is generally as small as possible, since a large space has a strong negative
effect on performance. It is the main source of the low power factor in which the engines work.
The magnetization current increases with airspace. For this reason, airspace should be minimal.
Very small spaces can pose mechanical problems in addition to noise and leakage.

Windings: - The windings area unit cables placed in bobbins, typically wrapped around a core in
laminated soft iron to create magnetic poles once they area unit energized with current.
The electric machines area unit offered in 2 basic configurations of the poles of the magnetic
field: configurations of the outgoing and non-salient poles. within the salient pole machine, the
field of force of the pole is created by a winding round the pole beneath the face of the pole.
within the machine with not hot pole, or distributed field, or spherical rotor, the winding is
distributed within the grooves facing the pole. A secure pole motor encompasses a winding
around a region of the pole that delays the section of the field of force for that pole.
Some engines have conductors manufactured from thicker metals, like bars or metal sheets,
typically copper or Al. These area unit typically supercharged by magnetic force induction.

Switch: - A switch is a mechanism used to change the input of most DC machines and some CA
machines. Consists of segments of slip rings isolated from each other and the tree. The motor
armature current is supplied by fixed brushes in contact with the rotary switch, which causes the
required current to be reversed and applies the power to the machine optimally when the rotor
rotates from one pole to the other. In the absence of this current reversal, the motor would stop
braking. In light of the best technologies in the field of electronic control, sensorless control,
induction motor and permanent magnet motor, external and permanent magnetic induction
motors are moving electromechanically switched motors.

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 BELT PULLEY MECHANISM

A system of belts and pulleys will transmit rotation and power to different axes over long
distances and tight areas. to try to to this with one thing sort of a gear, otherwise you want loads
of gears, or terribly massive gears, and this may increase the value of a product fairly quickly.
Another advantage of a system of belts and simple machines on a gear system is that the
direction of rotation is preserved in a very normal belt and pulley transmission (although it are
often modified). If the driving simple machine turns in a very sure direction, the simple machine
can do a similar. this can be an enormous distinction compared to the gear mechanisms, within
which 2 adjacent gears rotate in opposite directions.
Most simple machine systems admit friction, which suggests that if one aspect of the belt and
therefore the simple machine system work along, the belt will slide against the simple machine if
necessary. whereas this could appear ugly, it's truly helpful as a result of it prevents the system
from stopping the engine by taking an excessive amount of torsion. Band saws square measure a
good example of this. The band saw blade could be a massive ring that acts as a belt and 2
massive pulleys rotate the band saw to chop it.

Types of Pulleys
There area unit some forms of pulleys that i will be able to make a case for, that apply to
differing types of block systems. These area unit the naming conventions for the essential forms
of pulleys. In future steps we are going to see however a number of them is applied to boost the
mechanisms.
drive block: "input" pulley of a two-pulley system. this is often the block whose shaft is driven
by one thing sort of a motor, a rod, or presumably another block if in an exceedingly larger
system. This block controls the movement of the belt.
driven block: "exit" pulley of a two-pulley system. this is often the rotating block because of the
movement of the belt.
pulley: a sort of driven block isn't meant to transmit energy through its axis. Free rotation,
whereas most of the driven pulleys area unit connected to different devices, like wheels or
actuators, through their shafts.
fixed block: a pulley whose shaft is mounted in position. it's attainable to rotate, however cannot
freely translate in any direction.
Movable block: a block which will rotate and move per the movements of the pulley or belt. this
is often ordinarily employed in systems and also the closing approach, i will be able to make a
case for later.
Idler: a smaller bum sort block usually wont to guide the cable and keep it on a particular path.
Drum: common pulleys have one slot for belts, chains or cables. The drums area unit abundant
wider pulleys, usually employed in cable systems, which permit the cable to wrap the drum
diameter many times.
Pinion: a pinion is employed to drive chain systems. it's teeth around its diameter to grip the
links of the chain and push them forward.

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Belt Drives
A belt and simple machine system is one in every of the best varieties of simple machine
systems. As delineated higher than, it contains 2 pulleys, one that drives the belt and one that's
radio-controlled by a belt. Belt transmissions will take many various forms; On the steps of the
tank, band saws and stitching machines. Below area unit the four commonest varieties of belts.
Round belts: the spherical belts have a crosswise crosswise crosswise profile. {they area unit
they're} used for lightweight hundreds and are typically made from rubber. All the "sides" of the
belt profile area unit identical, therefore it's doable to appreciate some simple machine systems
that act with the various sides of the belt to transmit the movement in a noteworthy method.
Flat belt: flat belts have an oblong section profile. In general, they're elastic, so they cut back the
vibration of the belt and, in general, don't want tensioners.
Toothed belt: toothed belts area unit like flat belts, except that they're toothed on the inner facet.
this permits additional precise management over the position of a mechanism and means power
is transmitted through the teeth rather than the friction between the belt and also the simple
machine. As a result, the toothed belts don't slip just like the alternative belts, therefore the
pulleys stay synchronic. Some mechanisms, like the sex chromosome frames, use toothed belts
and mount the components on the belts to ascertain their position.
V-belt: V-belts area unit the foremost common style of belt. they need a "V" or a quadrangle
cross section, that corresponds to the form of the simple machine on that they rest. V-belts
cannot slide out of their pulleys like a number of the opposite belts thanks to their crosswise.
Other varieties of straps area unit specific to sure things, however derive from these four
varieties of straps. The blade on a band saw, as an example, could be a style of flat belt, whereas
the steps of the tank area unit a kind of toothed belt.

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 BEARINGS

A bearing is an element of the machine that limits movement compared to the desired movement
and reduces the friction between the moving parts. The design of the bearing can, for example,
provide a free linear movement of the moving part or a free rotation around a fixed axis; or, it
can prevent movement by controlling the normal force vectors that influence the moving parts.
Most bearings facilitate the desired movement by minimizing friction. The bearings are
classified in general terms based on the type of operation, the permitted movements or the
directions of the loads (forces) applied to the parts.
Rotary bearings support rotating components such as shafts or shafts in mechanical systems and
transfer axial and radial loads from the load source to the supporting structure. The simplest form
of bearing, the sliding bearing, consists of a shaft that rotates in a hole. Lubrication is often used
to reduce friction. In ball bearings and roller bearings, to avoid sliding friction, the rolling
elements, such as rollers or circular-section balls, are located between the tracks or the guides of
the bearing assembly. There is a wide variety of bearing designs to allow you to properly meet
the needs of the application to achieve maximum efficiency, reliability, durability and
performance.
The term "bearing" derives from the verb "orso" a bearing that is an element of the machine that
allows one part to carry (ie to support) another. The simplest bearings are the bearing surfaces,
cut or formed in a single piece, with different degrees of control over the shape, size, roughness
and position of the surface. Other bearings are separate devices installed on a machine or part of
a machine. The most sophisticated bearings for the most demanding applications are very precise
devices; Its manufacture requires some of the highest standards of current technology.

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Ball bearing
A bearing may be a kind of rolling bearing that uses balls to take care of the separation between
the bearing races.
The purpose of a bearing is to scale back move friction and support radial and axial hundreds.
this is often achieved by victimisation a minimum of 3 tracks to contain the balls and transmit
the costs through the balls. In most applications, one run is fastened and also the different is
connected to the rotating assembly (for example a hub or a shaft). once one amongst the bearing
races turns, the balls additionally rotate. as a result of the balls area unit rolling, they need a far
lower constant of friction than once 2 flat surfaces slide against one another.
Ball bearings tend to own a lower load capability thanks to their size compared to different sorts
of rolling bearings thanks to the smaller space of contact between the balls and also the tracks.
However, they will tolerate a placement of internal and external races.

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 SHAFT

An axis is a rotating element of the machine, generally circular in cross-section, which is used
to transmit energy from one side to the other or from a machine that produces energy to an
energy-absorbing machine. The various members, such as pulleys and gears, are mounted on
this.
The types
They are mainly classified into two types.
• Transmission shafts are used to transmit energy between the source and the energy-absorbing
machine; for example counterweights and linear axes.
• The machine axes are an integral part of the machine itself, for example. crankshaft.
material
The material used for ordinary auctions is in mild steel. When high strength is required, an alloy
of steel such as nickel, nickel-chromium or chromium-vanadium is used.
The trees are generally formed by hot rolling and are finished to measure by cold drawing or
turning and grinding.
Tensions
The following voltages are induced in the axes.
1. Cutting stresses due to torque transmission (due to torsional load).
2. Bending stresses (traction or compression) due to the forces acting on the machine elements,
such as gears and pulleys, as well as to the weight of the shaft.
3. Tensions due to combined torsion and bending loads.
Design tensions
The maximum allowed stresses (design) in flexion (traction or compression) can be taken as:
1. 112 N / mm2 for shafts with tolerance for keyways.
2. 84 N / mm2 for shafts without space for keys.
The maximum allowed cutting forces (design) can be taken as:
1. 56 N / mm2 for shafts with tolerance for keyways.
2. 42 N / mm2 for shafts without space for keys.

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 FRAME

Frames and machines are built-up structural and mechanical systems consisting of multiple parts
assembled together in a number of possible ways. For example, the parts could be pin-connected
or welded together. The primary difference between frames and machines is that there are
moving parts in machines and not in frames. The method of analysis is the same. Although
machines involve moving parts, we analyze the system at one instant in time when the positions
of individual parts and the applied loads are clearly defined. The solution to these systems
usually requires the drawing of the free-body diagrams of individual parts, and the application of
the equilibrium equations. Therefore, one must be careful in recognizing the existance of two-
force members that would identify the direction of the unknown force.

When a frame or machine is broken up into multiple parts, the forces and/or moments present at
the points of separation must be shown on the free-body diagrams of the separated parts in a
manner consistent with the third law of Newton. That is the forces and moments are shown as
equal and opposite on the two parts that have been separated.

The frame which is being used here is of dimension (22”×22”×25”). Mild steel is used to make
the structure of the machine rugged and stable which provides enough support to with stand the
vibration and unbalanced forces produces by the motor and movement of shafts while the
machine is in operating condition.

Basically a cuboid like structure is made by welding the (1”×1”) square pipe separated by
required dimensions. An intermediate shaft is placed between motor and cutter shaft supported
by ball bearings to obtain smooth rotational motion. At the top the cutter shaft is placed, the
bearing of which are fastened using nut and bolt on the frame. The top of the machine is covered
by a metal sheet in order to provide a platform for cutting operation.

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 CUTTER

 Mainly suited for cutting plates to size with straight cutting edgesˌ
 Table circular saws can be used with the right power drive for straight cuts of plates
 Saw blades should be made of hardened metal
 Use a sufficiently high enough feed rate and adequate offset
-Leads to good chip deflection.
-Avoids sticking of the saw blade.
-Avoids overheating of the plastic in the saw cut.
-Leads to good cutting edge quality.

Recommendations

 Use a corresponding tensioning device:

-Avoidance of vibrations and unclean cutting edges which can result from this,
or even lead to breakage.
 Warm cutting of very hard and fibre-reinforced materials (preheat to 175 – 250 °F).
 Tungsten carbide saw blades wear well and provide an optimum surface finish.

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 MATERIAL PROPETIES

MECHANICAL PROPERTIES OF MILD STEEL

Steel is created from carbon and iron, with way more iron than carbon. In fact, at the foremost,
steel will have regarding a pair of.1 % carbon. low-carbon steel is one amongst the foremost
usually used construction materials. it's terribly robust and might be made up of promptly offered
natural materials.

Chemistry
Mild steel typically contains forty points of carbon at the most. One carbon purpose is .01 % of
carbon within the steel. this implies that it's at the most .4 % carbon. Most steels produce other
alloying parts apart from carbon to present them sure fascinating mechanical properties. 1018
steel, a typical style of low-carbon steel, contains about .6 % to .9 % atomic number 25, up to .04
% phosphorus, and up to .05 % sulphur. variable these chemicals affects properties like corrosion
resistance and strength.
Physical Properties: Strength
Mild steel is incredibly robust thanks to the low quantity of carbon it contains. In materials
science, strength could be a sophisticated term. low-carbon steel features a high resistance to
breakage. Mild steel, as critical higher carbon steels, is kind of malleable, even once cold. this
implies it's high tensile and impact strength. Higher carbon steels typically shatter or crack
beneath stress, whereas low-carbon steel bends or deforms.
Quantitative Physical Properties
Mild steel features a density of .248 pounds per cubature unit. It melts at a pair of,570 degrees
physicist. it's a selected heat of around .122 British Thermal Units (BTU) per pound, per
cubature unit.
Usability
Mild steel is very fascinating for construction thanks to its weldability and machinability. thanks
to its high strength and physical property, it's quite soft. this implies that it will be simply
machined compared to tougher steels. it's conjointly simple to weld, each to itself and to
alternative varieties of steel. It takes on a pleasant end and is polishable. However, it can't be
hardened through heat treatment processes, as higher carbon steels will. this can be not entirely a
foul issue, as a result of tougher steels don't seem to be as robust, creating them a poor selection
for construction comes.

COMMERCIAL STEEL

A designation of a grade of steel suitable for moderate forming processes. Material of this quality
is ductile enough to be bent flat on itself in any direction in a standard bending process. The term
is commonly used to designate mild steel. Also known as CS (commercial steel) or CQ
(commercial quality). Also see deep-drawing steel, drawing steel, and extra-deep-drawing steel.
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SHEET METAL
Sheet metal is metal fashioned by associate degree process into skinny, flat items. sheet is one
among the elemental forms employed in shaping and it is cut and bent into a range of shapes.
unnumberable everyday objects are fictitious from sheet. Thicknesses will vary significantly;
very skinny sheets are thought of foil or leaf, and items thicker than half dozen millimetre (0.25
in) are thought of plate steel or "structural steel."
Sheet metal is on the market in flat items or rolled strips. The coils are fashioned by running
never-ending sheet of metal through a roll slitter.
In most of the planet, sheet thickness is systematically laid out in millimeters. In the US, the
thickness of sheet is often fixed by a standard, non-linear live referred to as its gauge. The larger
the gauge variety, the agent the metal. usually used steel sheet ranges from thirty gauge to
concerning seven gauge. Gauge differs between ferric (iron based) metals and nonferrous metals
like metallic element or copper. Copper thickness, as an example, is measured in ounces;
representing the burden of copper contained in a locality of 1 area unit. components factory-
made from sheet should maintain the same thickness for ideal results.
There ar many alternative metals which will be created into sheet, like Al, brass, copper, steel,
tin, nickel and metal. For ornamental uses, some vital sheet metals embody silver, gold, and Pt.
Sheet metal is employed in automobile and truck (lorry) bodies, plane fuselages and wings,
medical tables, roofs for buildings (architecture) and lots of alternative applications. sheet of iron
and alternative materials with high magnetic permeableness, additionally referred to as laminated
steel cores, has applications in transformers and electrical machines. traditionally, a crucial use
of sheet was in armour plate worn by cavalry, and sheet continues to own several ornamental
uses, as well as in horse tack. sheet staff also are referred to as "tin bashers" (or "tin knockers"), a
reputation derived from the pound of panel seams once putting in tin roofs.

TUNGSTEN CARBIDE

Tungsten carbide (chemical formula: WC) is a chemical compound (specifically, a carbide)

containing equal parts of tungsten and carbon atoms. In its most basic form, tungsten carbide is a
fine gray powder, but it can be pressed and formed into shapes through a process called sintering
for use in industrial machinery, cutting tools, abrasives, armor-piercing rounds, other tools and
instruments, and jewelry.

Tungsten carbide is approximately twice as stiff as steel, with a Young's modulus of

approximately 530–700 GPa (77,000 to 102,000 ksi), and is double the density of steel—nearly
midway between that of lead and gold. It is comparable with corundum (α-Al
2O3) in hardness and can only be polished and finished with abrasives of superior hardness such

as cubic boron nitride and diamond powder, wheels, and compounds.

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 CALCULATIONS

Desired Speed of cutter

Inbuilt speed of motor = 1500 r.p.m

Pulley attached to the motor = 2” diameter

Now by using the formula :-

N1 𝐷
= D2
N2 1

By taking the diameter of intermediate pulley to be 2”

1500 2
=2
𝑁2

Therefore , N2 = 1500 r.p.m

Now the diameter of the pulley at output shaft to be 2” and at intermediate shaft 5”we get the
desired cutter speed of 3000 r.p.m

N2 2
=5
N3

1500 2
=
𝑁3 5

Therefore, N3 = 3750 r.p.m

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 Design of shaft
R.P.M of motor = 1440 r.p.m

Power of motor = 1 HP = 746 watt

2𝜋𝑁𝑇
P= 60
𝑃∗60
T= 2𝜋𝑁
746∗60
T = 2∗3.14∗1440

Therefore, T = 4.9495 Nm

Teq = √𝑇 2 + 𝑀2
Neglegting the mass of pulley

Teq =√𝑇 2 = √4.9495 = 2.2247

Therefore, Teq = 2.2247 Nm

𝜋∗𝑑3 ∗𝜏𝑝𝑒𝑟
For safe design:- Τeq = 16

3.14∗𝐷3 ∗60
2.2247 = 16

Therefore, Diameter of shaft (D) = 0.018 m

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Power Required For The Operation :-

Shear stress of the composite material = 14 MPa

Area of the cutting surface

Width of the cutting surface = 5mm

Thickness of the cutter = 2mm

Area = (5*2)*10−6 m

Force required for cutting

F = σ*A

F = 14*106 *5*10−3*2*10−3

F = 140 N

Velocity of the cutter

πDN
V=
60
3.14∗0.211∗2000
V=
60
V = 22.1 m/s

Power (P) = Force * Velocity

P = 140*22.1

Therefore, POWER = 3094 Watt

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Calculation of belt length :-

1. Length from motor to intermediate shaft :-

𝜋(D2 +D1 ) (D2 +D1 )2

L1 = 2C + +
2 4𝐶
Where L = belt length in inches

C = centre length between two pulley’s in inches

D2 = Diameter of second pulley

D1 = Diameter of first pulley

π(2+2) (2+2)2
L1 = 2*15.75 + +
2 4∗15.75

L1 = 38 inches

2. Belt length from intermediate shaft to cutting shaft

π(5+2) (5+2)2
L2 = 2*11.5 + +
2 4∗11.5

L2 = 35 Inches

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 Performing Various Operations

Cutting of Sheet Metal

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Cutting of Shaft

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Performing Drilling Operation

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(19)
 CATIA DESIGN

Top View of the Machine

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Side View of the Machine

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Front View of the Machine

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Isometric view of the machine

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 Bill of materials
S No. Particular Description Quantity

1 Square pipe 1”×1” 28’

2 Solid Shaft 18mm dia 1meter

3 V belt B 35 type 1 no.

4 V Belt B 38 type 1 no.

5 Angle 1½”×1½” 4’

6 Pulley 2” 3no.

7 Pulley 5” 1no.

8 Motor 1HP/1Ø 1no.

9 Cutter Tungsten 1no.

carbide(4”dia)
1no.

10 Nut Bolt 12no.

11 washer 24no.

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 References

1. Handbook of Properties of Engineering Materials And Design Data For Machine

Elements by Abdulla Shariff.

2. Theory of machines by Ss rattan , Edition2005

3. Theory of machines by RS Khurmi, edition 2004

4. http://www.matweb.com/reference/composites.aspx

5. https://en.wikipedia.org/wiki/Carbon_steel

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